Self-adhesive membrane

ABSTRACT

A decoupling assembly for positioning between an underlying surface and a flooring material, the decoupling assembly including a decoupling membrane having a base panel having opposing upper and lower surfaces and a plurality of projections extending from the lower surface for contacting an underlying surface and supporting the base panel above the underlying surface. Each projection includes a bottom surface. The assembly further includes a plurality of adhesive fasteners, each adhesive fastener having an inner surface fixed to the bottom surface of a respective one of the plurality of projections, and an adhesive outer surface opposite the inner surface. The assembly further includes a plurality of release members, each release member covering the outer surface of one respective adhesive fastener, each release member being removable to expose the outer surface of the respective adhesive fastener for adhering the decoupling membrane to the underlying surface.

This application claims the benefit of Provisional Application Ser. No.61/753,965, filed Jan. 18, 2013, which is hereby incorporated herein byreference.

FIELD

The present subject matter of the teachings described herein relatesgenerally to membranes for covering an underlying surface, such as afloor, wall and/or other partition, to provide a mounting surface for acovering material.

BACKGROUND

U.S. Pat. No. 8,112,827 (DeGooyer et al.) discloses a shower drainadapter system configured to allow use of a bondable waterproof membranewith a shower pan drain system comprises a drain body and an integratedbonding flange extending upwardly from the drain body. The integratedbonding flange is operable to be sealably attached to a bondablewaterproof membrane to provide a substantially waterproof seal betweenthe membrane and the adapter. A lower mating flange is separable fromthe drain body, the lower mating flange operable to mate with acomponent of a shower pan drain system installable on a waste pipe. Thelower mating flange includes a substantially rigid frame; and a pliablegasket disposed at least partially about the frame, the pliable gaskethaving an inner diameter sized to correspond to an outer diameter of aportion of the drain body.

U.S. Pat. No. 4,917,933 (Schluter) discloses a plastic sheet which isused as a subcarrier for insulating linings of building surfaces. Thesheet is formed by parallel, alternating, dovetail-shaped channels andgrooves. A coarse-meshed lattice matting, having filaments, is glued orpartially fused to the backside of the plastic sheet and serves toanchor the sheet to the underlying foundation. This lattice mattingstretches over the entire backside or inner surface of the sheet. Thewebs of the plastic sheet are expandable and can compensate for stressesoccurring between the underlying foundation and the external facingmaterial such as ceramic tile.

SUMMARY

This summary is intended to introduce the reader to the more detaileddescription that follows and not to limit or define any claimed or asyet unclaimed invention. One or more inventions may reside in anycombination or sub-combination of the elements or process stepsdisclosed in any part of this document including its claims and figures.

According to one broad aspect of the teachings disclosed herein, adecoupling assembly for positioning between an underlying surface and aflooring material may include a decoupling membrane. The decouplingmembrane may have a base panel having opposing upper and lower surfacesand a plurality of projections extending from the lower surface forcontacting an underlying surface and supporting the base panel above theunderlying surface. Each projection may have a bottom surface. Theassembly may also include a plurality of adhesive fasteners. Eachadhesive fastener may have an inner surface fixed to the bottom surfaceof a respective one of the plurality of projections, and an adhesiveouter surface opposite the inner surface. A plurality of release membersmay be provided. Each release member may cover the outer surface of onerespective adhesive fastener. Each release member may be removable toexpose the outer surface of the respective adhesive fastener foradhering the decoupling membrane to the underlying surface.

The combined area of the outer surfaces of the adhesive fastenersmeasured in a first plane containing the outer surfaces of the adhesivefasteners may be between about 35% and about 65% of an area of the basepanel projected in the first plane.

At least some of the release members may be removable independently fromthe other release members.

At least some of the release members may be joined together to form arelease sheet. The release sheet may be removable in a single piece.

At least one adhesive fastener may be fixed to the bottom surface ofeach projection.

Adhesive fasteners may be provided on the bottom surfaces of only aportion of the plurality of projections.

Adhesive fasteners may be provided on the bottom surfaces of betweenabout 40% and 95% of the plurality of projections.

The adhesive fastener may be a hot melt adhesive, and/or a pressuresensitive adhesive. In some examples, the adhesive may be a lowviscosity hot melt named HL-8128X, made available by H.B. FullerCompany.

The base panel and release members may be rollable while coupledtogether to configure the decoupling assembly in a rolled configurationthat includes radially alternating layers of the base panel, theadhesive fastener and the release member. In the rolled configuration atleast one release member may be positioned radially between the outersurface of adhesive fastener on the bottom surface of one projection andat least a portion of the upper surface of the base panel.

Each projection may include a root portion adjacent the lower surface ofthe base panel, and a tip portion comprising the bottom surface andspaced apart from the lower surface of the base panel. Each projectionmay generally taper laterally inwardly from the tip portion to the rootportion.

Projection may include at least one sidewall extending between the rootportion and the tip portion. The at least one sidewall may be inclinedat a first angle relative to a vertical plane. The first angle isbetween about 0 and about 15 degrees.

The at least one sidewall may include a first sidewall and a secondsidewall opposite the first sidewall. The first and second sidewalls maybe non-parallel and may converge toward the root portion.

Each projection may include a root portion adjacent the lower surface ofthe base panel, and a tip portion comprising the bottom surface andspaced apart from the lower surface of the base panel. Each projectionmay generally taper laterally inwardly from the root portion to the tipportion.

Each projection extends between a root portion adjacent the lowersurface of the base panel, and a tip portion spaced apart from the rootportion and comprising the bottom surface. The bottom surface may bespaced apart from the lower surface by a projection height that isbetween about 1 mm and about 5 mm.

The decoupling membrane may be formed from a resilient plastic materialand may be liquid impermeable.

According to another broad aspect of the teachings described herein, amethod of installing a decoupling membrane onto an underlying surfacemay include the step of providing a decoupling membrane having a basepanel having opposing upper and lower surfaces and a plurality ofprojections extending from the lower surface. Each projection mayinclude a bottom surface. A plurality of adhesive fasteners may beprovided. Each adhesive fastener may include an inner surface fixed tothe bottom surface of one projection and an adhesive outer surface. Aplurality of release members may be provided and each release member maycover one adhesive outer surface. The method may also include the stepsof removing the release members to expose the adhesive fasteners;positioning the decoupling membrane over the underlying surface; andbonding the exposed adhesive fasteners directly to the underlyingsurface to adhere the decoupling membrane to the underlying surface.

The step of bonding the exposed adhesive outer surfaces to theunderlying surface may be completed in the absence of an interveningbonding agent.

The release members may be individually removable or may be removed inunison.

According to another broad aspect of the teachings described herein, amethod of producing a decoupling assembly for covering an underlyingsurface may include the steps of:

a) forming a decoupling membrane having base panel having opposing upperand lower surfaces and a plurality of projections extending from thelower surface, each projection comprising a bottom surface;

b) fixing an adhesive fastener to bottom surface of at least some of theprojections, each adhesive fastener comprising an inner surface fixed tothe bottom surface of the respective projection and an adhesive outersurface; and

c) covering each adhesive outer surface with a removable release member.

The method may also include the step of rolling the base panel andrelease members together to provide a generally cylindrical rolledmember, wherein at least one removable release member is positionedradially intermediate one adhesive fastener and a portion of the uppersurface.

DRAWINGS

The drawings included herewith are for illustrating various examples ofarticles, methods, and apparatuses of the teaching of the presentspecification and are not intended to limit the scope of what is taughtin any way.

In the drawings:

FIG. 1 is a perspective view of a portion of a decoupling membrane;

FIG. 2 is a bottom view of the portion of the decoupling membrane ofFIG. 1;

FIG. 3 is an end view of a decoupling membrane;

FIG. 4 is a perspective view of the decoupling membrane of FIG. 3 in arolled configuration;

FIG. 5 is an enlarged view of a portion of the decoupling membrane ofFIG. 4;

FIG. 6 is an enlarged view of a portion of the decoupling membrane ofFIG. 3;

FIG. 7 is a side view of a flooring system including a decouplingmembrane;

FIG. 8 is a sectional view of a portion of the flooring system of FIG.7, taken along line 8-8;

FIG. 9 is side view of another example of a decoupling membrane;

FIG. 10 is a bottom view of a portion of the decoupling membrane of FIG.9;

FIG. 11 is a side view of a portion of another example of a decouplingmembrane;

FIG. 12 is a block diagram of a method of installing a decouplingmembrane for over an underlying surface; and

FIG. 13 is a block diagram of method of producing a decoupling membrane.

DETAILED DESCRIPTION

Various apparatuses or processes will be described below to provide anexample of an embodiment of each claimed invention. No embodimentdescribed below limits any claimed invention and any claimed inventionmay cover processes or apparatuses that differ from those describedbelow. The claimed inventions are not limited to apparatuses orprocesses having all of the features of any one apparatus or processdescribed below or to features common to multiple or all of theapparatuses described below. It is possible that an apparatus or processdescribed below is not an embodiment of any claimed invention. Anyinvention disclosed in an apparatus or process described below that isnot claimed in this document may be the subject matter of anotherprotective instrument, for example, a continuing patent application, andthe applicants, inventors or owners do not intend to abandon, disclaimor dedicate to the public any such invention by its disclosure in thisdocument.

Decoupling membranes may be used when installing covering material,including for example ceramic tiles, stone tiles and other suchflooring, over an underlying surface. The underlying surface may be asubfloor, wall, stair case or any other type of partition or surface.The underlying surface may be formed from any suitable material,including, for example wood, concrete, particle board, oriented strandboard (OSB) drywall, and sheetrock.

The decoupling membrane can be positioned between the underlying surfaceand the covering material to help decouple or isolate the coveringmaterial from the underlying surface. To provide an assembled coveringsystem, the decoupling membrane is bonded to the underlying surface, andthen the floor covering material is bonded to an upper surface of thedecoupling membrane. The decoupling membrane may be somewhat flexibleand/or resilient to help isolate the covering material from theunderlying surface.

For example, the decoupling membrane may help prevent stress transferfrom the underlying surface to the covering material. Preventing stresstransfer may help prevent covering materials, such as tiles, fromcracking, loosening or otherwise being damaged as a result of movementof the underlying surface.

Optionally, the decoupling membrane may be liquid impermeable and/orvapour impermeable. Providing an impermeable membrane may help preventthe transfer of water or moisture between the underlying surface and thefloor covering.

Referring to FIG. 1, an example of a decoupling membrane 100 includes abase panel 102 having opposing upper and lower surfaces 104 and 106 anda plurality of projections 108 extending from the lower surface 106 (seealso FIG. 3). The projections 108 are for contacting an underlyingsurface 110 (FIG. 7), such as a subfloor, and supporting the lowersurface 106 above the underlying surface 110.

Referring to FIG. 7, when installed as part of a flooring system, thedecoupling membrane 100 is positioned between the underlying surface 110(e.g. a subfloor) and the floor covering material 112 (e.g. tiles). Inthe illustrated example, the decoupling membrane 100 is adhered to theunderlying surface 110 via the adhesive fasteners 114 on the bottoms ofthe projections 108, and the upper surface 104 (and interiors of theprojections 108) is coated with a conventional bonding compound 116,such as thin-set mortar. The floor covering tiles 112 are place on topof the layer of thin-set 116, and joints 118 between the tiles 112 arefilled with mortar 120.

Referring to FIG. 3, the base panel 102 and projections 108 may beformed from any suitable material, including for example, polypropylene,plastic and rubber. Optionally the base panel 102 and projections 108can be formed to be generally vapour and/or liquid impermeable.Alternatively, the base panel 102 and/or the projections 108 may bevapor and/or liquid permeable. In the illustrated example, the basepanel 102 and projections 108 are integrally formed together, such thatthey are of integral, one-piece construction. Alternatively, theprojections 108 and base panel 102 may be formed from separate membersthat are joined or coupled together.

The material used to form the base panel and/or projections may beresilient, elastic and be selected to have the desired mechanicalproperties (strength, etc.) to withstand the expected loading to whichthe decoupling membrane may be subjected.

Referring to FIG. 6, each projection 108 includes a bottom surface 122for engaging the underlying surface 110. Referring also to FIG. 3,adhesive fasteners 114 are fixed to the bottom surfaces 122 of theprojections 108. Each adhesive fastener includes an inner surface 115that is bonded to the bottom surface 122 of a respective projection 108,and an opposed outer surface 117.

The adhesive fasteners 114 may be any suitable type of fastening memberthat is operable to bond the bottom surfaces of the projections to theunderlying surface, including, for example, a layer or bead of chemicaladhesive or glue. Examples of suitable adhesives include glues, contactcement, double-sided tape, or other adhesives. In the exampleillustrated, the adhesive fastener is a hot melt pressure sensitiveadhesive made available by H.B. Fuller Company.

Optionally, the adhesive may be applied directly to the bottom surfaces122 in any suitable manner (rolling, spraying, coating, etc.) so thatwhen the adhesive dries an inner surface of the layer of adhesive isbonded to the bottom surface 122 and an opposing outer surface of theadhesive layer is exposed for bonding to the underlying surface. In thisconfiguration the inner and outer surfaces of the layer of adhesive canprovide the inner and outer surfaces 115 and 117, respectively.Alternatively, the adhesive fasteners may include a layer of adhesivethat is carried on a suitable substrate. For example, the adhesivefastener 114 may include a substrate having a first surface coupled tothe bottom surface 122 of a projection 108, and an opposed secondsurface that is coated with adhesive. The first surface can be coupledto the bottom surface 122 of the projections using any suitablemechanism, including an adhesive and a mechanical fastener. In thisconfiguration, the inner surface of the adhesive layer would be bondedto the second surface of the substrate, and the outer surface of theadhesive layer would be exposed for bonding to the underlying surface.Accordingly, the outer surface 117 can be provided by the outer surfaceof the adhesive layer and the inner surface 115 can be provided by thesubstrate or fastening mechanism used to secured the substrate to theprojection 108.

Optionally, each adhesive fastener 114 may cover only a portion of thebottom surface 122 of its corresponding projection 108, as shown forexample in FIG. 2. Alternatively, substantially the entire bottomsurfaces 122 of the projections 108 may be coated with a suitableadhesive, as shown in FIGS. 3 and 6.

Referring to FIG. 2, in the illustrated example, adhesive fasteners 114are provided on all of the bottom surfaces 122, such that eachprojection 108 are individually adhered to the underlying surface 110.Alternatively, adhesive fasteners 114 may only be provided on some ofthe bottom surfaces 122, such that only some of the projections 108 arebonded to the underlying surface 110. For example, adhesive fastenersmay be provided on the bottom surfaces of only a portion of theprojections 108, and optionally may be provided on the bottom surfacesof between about 40% and about 95% of the projections 108 or may beprovided on the bottom surfaces of between about 70% to about 90% of theprojections.

In the illustrated example, the adhesive fasteners 114 on the bottoms122 of the projections 108 are sticky at the time of manufacture, andremain sticky until bonded to the underlying surface 110. The adhesivefasteners do not need to be activated or otherwise treated to becomesticky. Having a plurality of projections 108 provided with exposed,sticky adhesive fasteners may make it difficult to handle or transportthe membrane.

Referring to FIG. 3, in the illustrated example, at least one releasemember 124 is provided to cover the adhesive outer surface 117 of eachadhesive fastener 114, to prevent the adhesive outer surface 117 frombeing exposed during transport of the membrane 100. Each release member124 includes an inner surface 126, facing the lower surface 106 andbonded to the adhesive fasteners 114, and an outer surface 128 oppositethe inner surface 126.

When the decoupling membrane 100 is at its desired destination, forexample at the location where it is intended to be installed, therelease member 124 is removed to expose the adhesive fasteners 114. Theexposed adhesive fasteners 114 can then be pressed against theunderlying surface 110 to adhere the decoupling membrane 100 to theunderlying surface 110.

Optionally, each release member 124 may be an individual or discretemember. In this configuration, the release members 124 may beindependently removable. This may allow a user to expose some of theadhesive outer surfaces 117, while leaving others covered. This mayfacilitate a staged uncovering of the adhesive fasteners as thedecoupling membrane is rolled out or installed. Alternatively, eachrelease member 124 may be a portion of a larger release sheet, or othersuitable member. In this configuration, the release members 124 arejoined together and can be removed together. Optionally, the releasesheet can be removable in a single piece, including all of the releasemembers 124. Alternatively, portions or groups of the release members124 may be joined together to form two or more release sheets. Eachrelease sheet may be removable independently of the other releasesheets, but may include multiple release members 124 which would beremoved in unison.

The release members 124 may be formed from any suitable material thatcan be releasably bonded to the adhesive fasteners 114. Preferably, therelease members 124 are formed from a material, or otherwise coated ortreated, such that the bond strength between the adhesive fasteners 114and the bottom surfaces 122 of the projections 108 is greater than thebond strength between the adhesive fasteners 114 and the release members124. If the release members 124 are joined together to form one or morerelease sheets, the entire sheet may be formed from the release sheetmaterial or coated/treated, or only portions of the sheet that form therelease members 124 may be treated.

To install a conventional decoupling membrane, an underlying surface isfirst covered with an adhesive compound (e.g. thin set) and the membraneis then pressed onto the thin set. A second layer of adhesive compoundis applied to the upper surface of the membrane to secure the coveringmaterial to the membrane. Providing a self-adhesive decoupling membrane100, having one or more adhesive fasteners 114 positioned on the bottomsurfaces 122 of the projections 108, may eliminate the need to use aseparate bonding agent, such as thin-set mortars, chemical adhesives orother adhesive mortars, to fasten the decoupling membrane to theunderlying surface. In the illustrated example, the adhesive fasteners114 can be directly bonded to the underlying surface 110 (FIG. 7),without the need for a separate layer of adhesive compound between themembrane 100 and the underlying surface 110. This may help simplify theinstallation process. Conventional adhesive compounds can then beapplied to the upper surface 104 of the decoupling membrane 100 tosecure the floor covering material, for example tiles 112, to themembrane 100.

Using a conventional membrane, substantially all of the underlyingsurface is coated with thin-set prior to positioning the membrane. Asthe membrane includes a plurality of projections spacing its lowersurface from the underlying surface, typically only the projectionsactually contact the thin-set and there is no direct contact between thethin-set and the lower surface of the membrane. In conventional membraneinstallations, the thin-set located between the projections may notactually bond to anything, and may be wasted. That is, the area coveredby the thin-set is greater than the total area of the bottoms of theprojections. In contrast, providing adhesive fasteners on the bottoms ofthe projections may allow the total area covered by adhesive togenerally match the total area of the bottoms of the projections (whichmay be between about 35% and about 65% of the projected area of the basepanel), which may eliminate the need to spread unused adhesive compoundlocated between the projections and help reduce the total amount ofadhesive material used to secure the decoupling membrane in place.Reducing the amount of adhesive used may help reduce the cost ofinstalling the decoupling membrane.

Referring to FIG. 6, each projection may extend between a root portion130, adjacent the lower surface 106 of the base panel 102, and a tipportion 132, comprising the bottom surface 122. The distance 134 betweenthe bottom surface and the lower surface defines a projection height.The projection height 134 may be between about 1 mm and about 5 mm, andmay be about 3 mm.

Each projection 108 may include one or more sidewalls 136 extendingbetween the bottom surface 122 and the lower surface 106. Optionally, atleast some of the projections 108 can generally taper from the tipportion 132 to the root portion 130. In this configuration the rootwidth 138 is less than the tip width 140. In the illustrated example,the tip width 140 may be between about 2 mm and about 30 mm or greaterthan 30 mm, and the root width 138 may be between about 2 mm and about30 mm or greater than 30 mm.

In the illustrated example, the sidewalls 136 of the projections 108 areinclined at an angle 142 relative to the vertical direction. The angle142 may be between 0 and about 15 degrees, and may be between 0 andabout 5 degrees. In this configuration, the interior of each projectiondefines overhang regions 144, illustrated as the shaded area in FIG. 8.Providing such overhang regions 144 may help retain the adhesivecompound 116 applied to the top 102 of the decoupling membrane 100within the interior 146 of the projection 108. This may help secure theadhesive compound 116, and covering material 112 mounted thereto, to thedecoupling membrane 100.

Alternatively, instead of tapering from tip to root (i.e. narrowing froma greater width at the tip to a narrower width of the root), eachprojection may be of a different, suitable shape and may, for example,have vertical sidewalls (i.e. no taper where the tip width 140 equalsthe root width 138) or may generally taper from the root portion to thetip portion (i.e. the root width 138 is less than the tip width 140).While illustrated as generally square or rectangular in cross-sectionalshape, each projection may define a generally circular cross-sectionalshape (i.e. may be cylindrical or frusto-conical) or any other suitableshape. Optionally, the projections need not be of the samecross-sectional shape, and a single base panel may include projectionshaving two or more different cross-sectional shapes.

The strength of the connection between decoupling membrane 100 and theunderlying surface 110 may be based on the strength of the adhesivefasteners 114 and the surface area of the bottom surfaces 122 of theprojections 108, or a combination thereof. Optionally, the projections108 can be sized such that the combined area of the bottom surfaces 122measured in a first plane 150 (FIG. 3) containing the bottom surfaces122 may be between about 35% and about 65% of an area of the base panel102 projected in the first plane 150.

Optionally, the decoupling membrane 100 may be rolled up. This may makeit easier to store and/or transport the decoupling membrane 100.Referring to FIG. 4, in the illustrated example the base panel 102 andrelease members 124 may be rolled while coupled together to provide agenerally cylindrical rolled member 152. In this rolled configuration,the rolled decoupling membrane 100 includes radially alternating layersof the base panel 102, the adhesive fastener 114 and the release member124.

To help prevent the decoupling membrane from sticking to itself whenrolled, the release members 124 covering the adhesive fasteners 114 arepositioned radially between the adhesive fasteners 114 and an overlyingportion of the base panel 102 (for example the upper surface 104) thatis opposing, and optionally pressed against, the adhesive fastener 114in the rolled configuration. Referring to FIG. 5, in the illustratedexample a release member 124 is positioned radially between eachadhesive fastener 114 and a portion of the upper surface 104 of the basepanel 102.

Optionally, the release members 124 used to cover the adhesive fastenersmay comprise a plurality of separate release members, or at least someof the release members may be joined together to form one or morerelease sheets. Referring to FIG. 3, in the illustrated example all ofthe release members 124 are joined together to form one continuousrelease sheet. Providing a continuous release sheet may make it easierto apply the release members over the adhesive fasteners 114, and mayallow all of the release members 124 to be removed together. In thisconfiguration the release sheet may be removable as a single piece.

Referring to FIG. 9, another example of a self-adhesive decouplingmembrane 200 includes a base panel having a plurality of projections.The decoupling membrane 200 is generally analogous to the decouplingmembrane 100, and like features are represented using like referencecharacters indexed by 100.

In this example, adhesive fasteners 214 are only provided on the bottomsurfaces 222 of some of the projections 208. Each adhesive fastener 214is covered by a separate release member 224, which are not connected toform a single release sheet.

Referring to FIG. 10, another example of a self-adhesive decouplingmembrane 300 includes a base panel 302 having a plurality of projections308. The decoupling membrane 300 is generally analogous to thedecoupling membrane 100, and like features are represented using likereference characters indexed by 200.

In this example, adhesive fasteners 314 are only provided on every otherprojection 108 in each row and column of projections. While only some ofthe projections 208 are provided with adhesive fasteners 214, therelease members 224 covering each adhesive fastener 214 are connected toform a single release sheet, the perimeter of which is shown usingdashed lines for clarity.

Referring to FIG. 11, another example of a self-adhesive decouplingmembrane 400 includes a base panel 402 having a plurality of projections408. The decoupling membrane 400 is generally analogous to thedecoupling membrane 100, and like features are represented using likereference characters indexed by 300.

In this example, the projections 408 extending from the lower surface406 of the base panel 402 are configured such that they taper from root430 to tip 432, and that the root width 438 is greater than the tipwidth 440.

Referring to FIG. 12 a method 1200 of installing a decoupling membranefor over an underlying surface may include, at step 1202 providing aself-adhesive decoupling membrane having a base panel having opposingupper and lower surfaces and a plurality of projections extending fromthe lower surface for contacting the underlying surface and supportingthe lower surface above the underlying surface. Each projection mayinclude a bottom surface for engaging the underlying surface. Anadhesive fastener may be fixed to at least some of the bottom surfaces,and a release member may cover each adhesive fastener

At step 1204, the method may include removing the release members toexpose the adhesive fasteners and, at step 1206 positioning thedecoupling membrane over the underlying surface. Step 1208 includesbonding the exposed adhesive fasteners directly to the underlyingsurface to adhere the decoupling membrane to the underlying surface.Optionally, step 1208 may include bonding the adhesive fastenersdirectly to the underlying surface and can be completed in the absenceof an intervening layer of bonding agent or compound.

Referring to FIG. 13, a method 1300 of producing a self-adhesivedecoupling membrane for covering an underlying surface may include, atstep 1302, forming a base panel having opposing upper and lower surfacesand a plurality of projections extending from the lower surface forcontacting an underlying surface and supporting the lower surface abovethe underlying surface. Each projection may have a bottom surface. Atstep 1304, an adhesive fastener is fixed to at least some of the bottomsurfaces. This step may include spraying, spreading or otherwise coatingthe bottom surfaces with a chemical adhesive, and/or may include placingone or more discrete chemical fasteners (e.g. double side tape, etc.) oneach bottom surface.

At step 1306, each adhesive fastener is covered with a removable releasemember.

Optionally, the method may also include the step 1308 of rolling thebase panel and release members together to provide a generallycylindrical rolled member, in which at least one removable releasemember is positioned radially intermediate one adhesive fastener and aportion of the upper surface.

Optionally, any of the features of any of these examples may be usedalone or in combination or sub-combination with each other. What hasbeen described above has been intended to be illustrative of theinvention and non-limiting and it will be understood by persons skilledin the art that other variants and modifications may be made withoutdeparting from the scope of the invention as defined in the claimsappended hereto.

1. A decoupling assembly for positioning between an underlying surfaceand a flooring material, the decoupling assembly comprising: a) adecoupling membrane comprising a base panel having opposing upper andlower surfaces and a plurality of projections extending from the lowersurface for contacting an underlying surface and supporting the basepanel above the underlying surface, each projection comprising a bottomsurface; b) a plurality of adhesive fasteners, each adhesive fastenercomprising an inner surface fixed to the bottom surface of a respectiveone of the plurality of projections, and an adhesive outer surfaceopposite the inner surface; and c) a plurality of release members, eachrelease member covering the outer surface of one respective adhesivefastener, each release member being removable to expose the outersurface of the respective adhesive fastener for adhering the decouplingmembrane to the underlying surface.
 2. The decoupling assembly of claim1, wherein the combined area of the outer surfaces of the adhesivefasteners measured in a first plane containing the outer surfaces of theadhesive fasteners is between about 35% and about 65% of an area of thebase panel projected in the first plane.
 3. The decoupling assembly ofclaim 1, wherein at least some of the release members are removableindependently from others of the release members.
 4. The decouplingassembly of claim 1, wherein at least some of the release members arejoined together to form a release sheet, the release sheet beingremovable in a single piece.
 5. The decoupling assembly of claim 1,wherein at least one adhesive fastener is fixed to the bottom surface ofeach projection.
 6. The decoupling assembly of claim 1, wherein adhesivefasteners are fixed on the bottom surfaces of only a portion of theplurality of projections.
 7. The decoupling assembly of claim 6, whereinadhesive fasteners are fixed on the bottom surfaces of between about 40%and 95% of the plurality of projections.
 8. The decoupling assembly ofclaim 1, wherein the adhesive fastener comprises a hot melt pressuresensitive adhesive.
 9. The decoupling assembly of claim 1, wherein thebase panel and release members are rollable while coupled together toconfigure the decoupling assembly in a rolled configuration thatincludes radially alternating layers of the base panel, the adhesivefastener and the release member.
 10. The decoupling assembly of claim 9,wherein in the rolled configuration at least one release member ispositioned radially between the outer surface of adhesive fastener onthe bottom surface of one projection and at least a portion of the uppersurface of the base panel.
 11. The decoupling assembly of claim 1,wherein each projection comprises a root portion adjacent the lowersurface of the base panel, and a tip portion comprising the bottomsurface and spaced apart from the lower surface of the base panel, andwherein each projection generally tapers laterally inwardly from the tipportion to the root portion.
 12. The decoupling assembly of claim 11,wherein each projection includes at least one sidewall extending betweenthe root portion and the tip portion, and wherein the at least onesidewall is inclined at a first angle relative to a vertical plane. 13.The decoupling assembly of claim 12, wherein the at least one sidewallcomprises a first sidewall and a second sidewall opposite the firstsidewall, and wherein the first and second sidewalls are non-paralleland converge toward the root portion.
 14. The decoupling assembly ofclaim 12, wherein the first angle is between about 0 and about 15degrees.
 15. The decoupling assembly of claim 1, wherein each projectioncomprises a root portion adjacent the lower surface of the base panel,and a tip portion comprising the bottom surface and spaced apart fromthe lower surface of the base panel, and wherein each projectiongenerally tapers laterally inwardly from the root portion to the tipportion.
 16. The decoupling assembly of claim 1, wherein each projectionextends between a root portion adjacent the lower surface of the basepanel, and a tip portion spaced apart from the root portion andcomprising the bottom surface, and wherein the bottom surface is spacedapart from the lower surface by a projection height that is betweenabout 1 mm and about 5 mm.
 17. The decoupling assembly of claim 1,wherein the decoupling membrane is formed from a resilient plasticmaterial.
 18. The decoupling assembly of claim 1, wherein the decouplingmembrane is liquid impermeable.
 19. A method of installing a decouplingmembrane onto an underlying surface, the method comprising the steps of:a) providing a decoupling membrane having a base panel having opposingupper and lower surfaces and a plurality of projections extending fromthe lower surface, each projection comprising a bottom surface, aplurality of adhesive fasteners, each adhesive fastener comprising aninner surface fixed to the bottom surface of one projection and anadhesive outer surface, and a plurality of release members, each releasemember covering one adhesive outer surface; b) removing the releasemembers to expose the adhesive outer surfaces; c) positioning thedecoupling membrane over the underlying surface; and d) bonding theexposed adhesive outer surfaces directly to the underlying surface toadhere the decoupling membrane to the underlying surface.
 20. The methodof claim 19, wherein step d) is completed in the absence of anintervening bonding agent.
 21. The method of claim 19, wherein therelease members are individually removable.
 22. The method of claim 19,wherein step b) includes removing all of the release members in unison.23. A method of producing a decoupling assembly for covering anunderlying surface, the method comprising the steps of: a) forming adecoupling membrane having base panel having opposing upper and lowersurfaces and a plurality of projections extending from the lowersurface, each projection comprising a bottom surface; b) fixing anadhesive fastener to bottom surface of at least some of the projections,each adhesive fastener comprising an inner surface fixed to the bottomsurface of the respective projection and an adhesive outer surface; andc) covering each adhesive outer surface with a removable release member.24. The method of claim 23, further comprising the step of rolling thebase panel and release members together to provide a generallycylindrical rolled member, wherein at least one removable release memberis positioned radially intermediate one adhesive fastener and a portionof the upper surface.